Load bed lift-roof cover

ABSTRACT

An attaching system for a lift-roof cover pivoting substantially about a fixed forward wall upper edge via application of rear hatch technology of the prior art for conventional cab high covers together with attachment means in the form of linkages. The attaching system for mounting to a load bed supports multiple functions providing convenience in distribution and installation processes; in particular facilitating use of processes employed for conventional caps with respect to shipping and storage. The system includes lift-roof to forward wall stop and side retainer means supporting improved functional integrity and security. Also included are draw latches supporting levels of operating convenience demanded for lift-roof applications. Simplified manufacturing adaptation of a conventional cap is supported by pre-assembly of key subassemblies. Capability for completing all functional adjustments before shipping supports installation simplified to levels suited to needs of multiple location installers experienced only with conventional covers of the prior art.

CROSS-REFERENCES TO RELATED APPLICATIONS

This invention defines improvements to the concepts described under U.S.Pat. No. 5,102,185 which is a continuation-in-part of Ser. No. 216,140,Jul. 7, 1988, abandoned, which is a continuation-in-part of Ser. No.52,906, May 22, 1987, U.S. Pat. No. 4,756,571.

© STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

REFERENCE TO A MICROFICHE APPENDIX

Not Applicable.

BACKGROUND OF THE INVENTION

(1) Technical Field

The invention pertains to lift-roof covers for use with load beds oflight trucks, providing improved access to the load bed and extendingfunctions to other uses, with major focus upon achieving these benefitsin a manner best accommodating manufacturing and distribution processesbroadly in use relative to conventional fixed mount cab high covers(caps) of the prior art. Applicable US classifications include296/100.1, 100.6 hinged load covers, 296/165 expansible or collapsiblevehicle body, 296/176 expansible/collapsible from a first to a secondconfiguration for camping. The disclosure describes key improvementsbeyond the concept described by U.S. Pat. No. 5,102,185, theseimprovements providing simplification in manufacturing processes andimprovements in convenience of installation and operation to levelsapproaching those for conventional fixed mount caps (cab high covers) ofthe prior art. These improvements also increase the functionalreliability of the complete lift-roof cover system and make possibleenhanced aesthetic appeal by eliminating obvious appearance differencesfrom conventional fixed mount caps of the prior art which havedemonstrated highest user acceptance levels. In particular, objectionhas been made to separation lines between the forward wall and thelift-roof/cap shell when these are visible in side view. The applicationto a new use of existing technology for hinging and weather sealing rearhatch assemblies for fixed mount caps of the prior art overcomes thisdeficiency, while supporting functional and economic benefits associatedwith use of technology which is familiar to practitioners of the art towhich the invention pertains.

(2) Description of Related Art

Through review of the prior art defined in patents relating to pickuptruck load bed covers issued subsequent to Lake, U.S. Pat. No.5,102,185, it can be seen that much effort has been focused on inventingalternate means to provide improved access for loading/unloading andfacilitating adaptation to uses beyond cargo protection while alsomaking available a roof height equal to or greater than that of thevehicle cab. Examples include the following:

Ekonen et al, U.S. Pat. No. 5,104,175, and Herndon, U.S. Pat. No.5,951,095, describe transformable cover assemblies which unfold from alow profile on the load bed to provide full enclosure with a roof levelequivalent to that of a cab high, fixed mount cap of the prior art.However, they add complexity while giving up significant degrees ofsecurity and integrity of appearance with the vehicle when in the cabhigh operating mode.

Plamondon, U.S. Pat. No. 6,149,217, Alexa, U.S. Pat. No. 6,000,745,Moberly, U.S. Pat. No. 5,443,295, and Hanning, U.S. Pat. No. 6,471,282,describe retractible flexible covers of cab height which fail to providethe security and integrated (with vehicle) appearance provided by mostfixed mount, molded caps.

Aragon et al, U.S. Pat. No. 5,516,182, Herzberg et al, U.S. Pat. No.5,203,603, and Hutchinson, U.S. Pat. No. 5,655,809, describe telescopingcab high covers having rigid outer paneling. These concepts providebetter cargo security, but add significant complexity and also fail toprovide the fully integrated appearance provided by most conventional,fixed mount, molded caps.

Fowler, U.S. Pat. No. 6,471,280, describes a cover with hard moldedshell but, in order to provide improved loading access, requires removalof the shell, an obvious inconvenience.

Baldwin, U.S. Pat. No. 6,439,647, Dence, U.S. Pat. No. 6,394,532, andLambden, U.S. Pat. No. 6,007,137, describe cab high rigid coverspivoting from one or both sides in a manner providing increased interiorvolume as desirable for adaptation to camping or improved side loadingaccess. However they fail to provide improved access from the rearsuitable for loading popular wheeled equipment.

Harkins, U.S. Pat. No. 5,209,543, describes an apparatus for enclosuressuch as pickup bed tops, including a pair of folding top panelslongitudinally hinged for closing along the top centerline. In order toachieve the benefits of lift-roof improved access loading from the rear,considerable and costly complexity is added.

Medlin, U.S. Pat. No. 5,595,418, and Enninga, U.S. Pat. No. 5,104,175,describe means for mounting a cap to a load bed in ways accommodatingpivotal rotation of the complete camper shell about a forward axis bylifting from the rear. However, significant complexity appears to beadded in hardware and processes necessary for installation andacceptable function. Furthermore, sealing at the forward wall to loadbed interface is not addressed.

Moore et al., U.S. Pat. No. 5,421,633, describes a camper shell intendedfor mounting directly to a truck frame on a vehicle assembly line,adaptable to having its roof pivotally raised from the rear and havingflexible walls for camping attached and/or removed. Moore et al appearsfocused on application of lift-roof functional benefits via a highproduction volume vehicle assembly process requiring high levels ofmanufacturing tooling investment and does not appear to address needs ofmanufacturing and distribution systems in place within the conventionalcap industry.

The concepts cited above provide various benefits beyond those providedby conventional fixed mount caps of the prior art. In most casescompromises are introduced which are evidently unacceptable to mostpurchasers of fixed mount, molded caps (historically comprising theprimary market for pickup truck covers), who demand an appearance wellintegrated with styling of the vehicle, together with secure,weatherproof enclosure of the load bed to a height matching that of thevehicle cab. It would appear that Enninga and Medlin are able to retainall key functional and aesthetic benefits provided by conventional capsas long as they are used in the closed condition. When in the opencondition cargo space is compromised, due to intrusion of the capforward wall, which moves rearward as the cap shell is raised andintroduces issues with respect to sealing to the load bed forward wall.Also, complexity introduced in the components and associated processesnecessary for installation become of particular concern whereinstallation may be completed at multiple locations by individuals withlimited experience relative to the product. Therefore, objects of myinvention include to provide the benefits of improved access for loadingand easy adaptation to alternate uses while minimizing complexity in theinstallation process and/or costs in added hardware and avoidingcompromises relative to benefits already provided by conventional fixedcaps of the prior art.

Grise, U.S. Pat. No. 4,452,482, and McGaughey et al, U.S. Pat. No.4,461,185, describe hatch frame construction for pickup truck capsincluding an integral hinge for supporting a hatch door in aweatherproof manner with location close to the cap roof edge. Thesepatents are of referent interest in describing adaptation of radius doortechnology to lift-roof cover application

Ely et al, U.S. Pat. No. 6,179,350, describes a draw latch and variousmeans for providing resistance to keep the members of a latch assemblyin a variety of given positions and addresses need for manually raisinga catch in order to effect disengagement.

Gromotka, U.S. Pat. No. 5,478,125, describes a draw latch in whichrotation of the lever initially disengages the catch and positivecontact between the lever and latch arm at a distance from the latchpivot causes the hook arm to kick out. Objects include to provide thesefunctions with parts which are few, durable and reliable in allfunctions.

P. R. Gley et al, U.S. Pat. No. 3,519,298, describes a positive lock fortoggle catch, or draw latch, permitting concomitant release of the catchand movement of the handle to an open position.

The above draw latch patents address need for one-handed convenience inoperation. Various methods are described as used in the prior art forpositioning handles and latch arms to support convenient operation.Plastic inserts have been employed where corrosion from exposure to theelements could otherwise impair function. Metal-to-metal frictionalmethods are commonly employed in order to support low cost. However, itwould appear that, in practice, most friction or interference methodstend to result in high efforts and/or variation in effort due to wearand/or manufacturing variability. Such methods may be adequate totemporarily retain latch handles to an open position, because full handstrength may be conveniently applied to effect release. However, thecontrol effort with respect to a latch arm pivoting from a latch handleneeds to be relatively low in order to support convenient operation,which requires moving the latch arm independently of the handle eitherimmediately before moving the handle, or simultaneously with handleoperation, but in any case as a fluid one-handed movement. Accordinglyit is an object to provide a draw latch which supports convenientpositioning of component parts in operation by applying reliable methodsto draw latches having other characteristics suited to lift-roof coverapplication. This may be best achieved with concepts depending on zeroresistance beyond that of a free pivot and force of gravity, orotherwise with a more reliable method of providing frictional resistancethan generally employed in the prior art.

SUMMARY OF THE INVENTION

To meet expectations with respect to product attributes broadly demandedwithin the primary market containing the majority of potential lift-roofcover users, these attributes must not be significantly compromised. Ofparticular importance for meeting needs of customers through the totaldelivery chain are convenience in manufacturing, distribution andinstallation as well as in end use. Accordingly, objects include toprovide a forward wall and attaching system which may be convenientlypre-assembled and stored ready for assembly with minimal rework to amolded reinforced plastic cover of the prior art (generally limited toremoval of material as needed to attach added hardware), together withan attaching system simplifying the process of installation to a vehicleload bed while supporting shipping, handling, storage methods employedfor conventional caps of the prior art. Subassemblies incorporating drawlatches and lift assist struts (plus rigid support struts and rigidsupport strut engagement means) are also used supporting theseobjectives. Draw latches have been uniquely developed for lift-roofapplication to provide reliable operating convenience.

To satisfy users, opening and closing operations must be convenientlycompleted by one person. Available draw latches of the prior art havebeen found lacking in functions necessary for such convenience. Latcheson each side of the cover need to be simultaneously operated with simplemovement of one hand, both in closing/latching and releasing/raising thecover. This requires reliable friction means and operating geometryensuring that, when the lift-roof cover has been lowered on the load bedand the latch handle is operated to effect engagement, the engaginglatch arm can be conveniently positioned to complete engagement and,after operation to effect release, remain in a position allowingunimpeded lift-roof raising or lowering.

A preferred forward wall is adapted from technology applied to rearhatch doors for conventional fixed caps of the prior art, generallyreferred to as radius doors in the trade to which the inventionpertains. Adaptation of extruded-frame-hinged-within-extruded-framepivotal attachment allows the forward wall to lift-roof structureinterface joint to be inboard of the lift-roof side walls and hidden asviewed from outside of the vehicle, a valuable aesthetic benefit.Related benefits of applying this proven technology to a new use includesimplified systems for lift-roof to forward wall hinging/sealing andorientation/position adjustment of the forward wall relative to loadbed.

A novel forward wall to load bed attaching system is in the form of alinkage which supports multiple functions, including providing (a) meansfor adjusting location of the forward wall on the load bed andorientation of the forward wall to achieve effective sealing in closedcondition between forward wall, lift-roof and load bed; (b) means ofconveniently completing installation or removal from the vehicle loadbed without fully removing attaching fasteners (c) in conjunction withlift assist struts, means to hold the forward wall to a closed positionrelative to the lift-roof with all components secured above a planeacross lower edges of the molded lift-roof, so that the completelift-roof cover may be shipped, handled and stored prior to installationusing the same methods employed for a conventional fixed mount cap ofthe prior art.

In use, the lift assist struts are mounted between the load bed andlift-roof structure in a manner (a) facilitating sealing at the forwardwall to lift-roof interface by loading the lift-roof forward against theforward wall and (b) adding lateral constraint in location of thelift-roof relative to load bed, providing protection from damage whichmight otherwise result, for example, from severe wind gustingimmediately on raising the lift-roof.

A durability concern for conventional caps of the prior art has relatedto effects of severe shake, as associated with some modes of heavy dutymodel pickup operation on rough road surfaces. Without countermeasures,lift-roof structure side wall forward lower edges have increasedsensitivity to lateral vibration compared with a conventional cap, inwhich the side walls are integral with the forward wall. Such vibrationis prevented by incorporation of side wall retainer means between thelift-roof structure and the forward wall structure. To accommodatedimensional variability, these units incorporate means for adjustment ofrelative lateral position.

The use of frame-hinged-within-frame radius door fabrication technologyin a forward wall to lift-roof attachment system results in forwardloads imposed by the lift assist struts being transferred to the forwardwall by the hinge interface when the lift-roof is in a raised position.Rigidity of the hinge interface protects the seal from excessivecompression in upper locations, so that with the lift-roof closed andwithout countermeasures, forward loading is transferred primarily to thelower edges of the inverted U shaped lift-roof side wall to forward wallinterface. This results in the seal and inner and outer frames deformingtoward the lower edges to a degree eventually impairing both sealing andpositioning of the lift-roof on the load bed. To avoid these conditionsand provide precise control of closed location of the lift-roof relativeto the forward wall, means of adjustable forward wall closure stop areneeded. This is achieved cost effectively by integrating such means ofadjustable stop with the adjustable lift-roof side wall retainers ateach side of the lift-roof cover. These integrated units allow closureposition to be set simultaneously with side wall retainer engagementduring assembly, protecting sealing function between the lift-roof andthe forward wall and preventing vibration of lift-roof side wallsrelative to the forward wall, as well as increasing security fromunauthorized forced entry.

Designing for flex under severe operating conditions has become broadlyrecognized as necessary for structures such as tall buildings andbridges in order to achieve reliability with acceptable cost. Thisconcept may have been less broadly recognized in automotive accessoryapplications and, perhaps as a result, fracturing of early molded capshells was not uncommon, particularly in cold climates. Therefore,manufacturers have developed caps which better absorb flex. Severeoperation results in significant torsional flexing of most pickup truckframes, much of which is transmitted to the load bed. If ignored, theeffects add cost in reliability and other functional respects. Flex maybe less of a concern with low frequency twist, as induced by normaloff-road operation. However, pickups, particularly heavy duty models,may induce severe lateral shake due to high rate suspension systemswhich, under some light load operating modes on rough road surfaces,instead of fully absorbing irregularities, cause high frequency shake tobe transmitted to the load box. Accordingly, it is an object of theinvention to address issues of structural flex under operatingconditions in lift-roof cover application.

In summary, the object of my invention is to add novel improvements withrespect to convenience, cost and reliability affecting assembly,distribution, installation and use while providing a combination ofadvantages relative to fixed mount covers of the prior art as describedin the parent U.S. Pat. No. 5,102,185 and fully maintaining the benefitsalready provided by conventional bed covers of the prior art. Furtherobjects and advantages will become readily apparent to those skilled inthe art to which the invention pertain upon reference to the followingdetailed description of a preferred embodiment.

DESCRIPTION OF THE DRAWINGS

The description refers to the accompanying drawings in which likereference characters refer to like parts throughout the several views.Much of what is described in the disclosure refers to one side of alift-roof cover. The other side may be assumed to be of like or mirrorimage form.

FIG. 1 is a perspective view looking forward of an improved lift-roofcover installed on a light truck load bed with the lift-roof structure(cap shell) in a raised condition.

FIG. 2 is a fragmentary sectional view from inside an installedlift-roof cover, looking toward its right side, showing a preferredforward wall attaching and adjusting means in form of linkages forattaching a lift-roof cover to a light truck load bed. The position ofcomponents with the lift-roof cover installed for use is shown in solidline and other positions are shown in broken line.

FIG. 3 is a fragmentary perspective view of a latch and strut pivotmount assembly as installed to the right side rail of a lift-roofstructure in closed condition.

FIG. 4 is a fragmentary sectional view looking forward along arrows 4—4of FIG. 5, showing a lift-roof to forward wall adjustable sideretention/stop means.

FIG. 5 is fragmentary sectional view downward along arrows 5—5 of FIG.4, showing forward wall sealing means and also a lift-roof to forwardwall adjustable side retention/stop means.

FIG. 6 is a fragmentary sectional view along arrows 6—6 of FIG. 5.

FIG. 7 is a fragmentary sectional view similar to FIG. 5 of an alternateside retention/stop means.

FIG. 8 is a fragmentary side elevation of an alternate forward wallattaching linkage means.

FIG. 9 is a fragmentary sectional plan view along arrows 9—9 of FIG. 8of an alternate forward wall attaching linkage.

FIG. 10 is a fragmentary sectional view along arrows 10—10 of FIG. 9.

FIG. 11 is a sketch depicting the lift-roof cover as initially placed ona load bed with latches engaged to hold desired location.

FIG. 12 is a sketch depicting the forward attaching linkage engaged withthe load bed.

FIG. 13 is a sketch depicting the lift-roof raised for attachment oflift assist strut lower pivots.

FIG. 14 is a sketch depicting the lift-roof lowered to levels at andnear (broken line) full closure.

FIG. 15 is a fragmentary view looking forward of a first draw latch ofthe prior art mounted to the left side of a lift-roof structure. Thefully latched condition is shown in broken line and an initial releasedcondition is shown in solid line.

FIG. 16 is a view looking forward of a first draw latch of the prior artas in FIG. 15, showing a desired operating condition following release.

FIG. 17 is a fragmentary view looking forward of a first improved drawlatch similar to the draw latch shown in FIGS. 17 and 18 except asdescribed for use in a lift-roof cover, mounted to the left side of alift-roof structure.

FIG. 18 is a fragmentary view along arrows 18—18 of FIG. 17.

FIG. 19 is a fragmentary view looking forward of a second draw latch ofthe prior art mounted to the left side of a lift-roof structure, in alatched condition.

FIG. 20 is a fragmentary view looking forward of a second draw latch ofthe prior art mounted to the left side of a lift-roof structure, in areleased condition.

FIG. 21 is a fragmentary view along arrows 21—21 of FIG. 20 of a seconddraw latch of the prior art mounted to the left side of a lift-roofstructure, in a released condition.

FIG. 22 is a fragmentary sectional view along arrows 22—22 of FIG. 23 ofa second improved draw latch similar to the draw latch shown in FIGS.19, 20 and 21 except as described, for use in a lift-roof cover, mountedto the left side of a lift-roof structure.

FIG. 23 is a fragmentary view along arrows 23—23 of FIG. 22 of a secondimproved draw latch for use in a lift-roof cover, mounted to the leftside of a lift-roof structure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1: The lift-roof cover 10 is mounted on a load bed 11including side walls 12 fabricated so that the outside vertical surface13 of the load bed wall 12 is continuous with the upper, substantiallyhorizontal surface 15 of the wall 12 and the surface 15 likewise iscontinuous with an inside vertical flange 16 formed approximately at 90degrees where it joins the upper surface 15, the flange 16 serving toadd rigidity to the upper surface 15, as needed under vertical loading,and extending downward typically one to two inches. The flange 16 isfully accessible along most of the length of the load bed 11 between theload bed forward wall 17 and rear end 18. Side walls 19 at left andright sides 20, 21 respectively of a lift-roof structure 22 incorporatewindows 14 and are joined at their lower edges 23 to substantiallyhorizontal structural rails 24 which terminate along their length at aninner edge 25 almost directly above the load bed flanges 16. The rails24 and side wall lower edges 23 match contours of the upper surfaces 15of the load bed side walls 12. Sealing means 26 are mounted along thelower surface of the lift-roof cover rails 24 to provide weather sealingbetween the load bed upper surfaces 15 and lift-roof structure 22 whenclosed.

Referring to FIGS. 1, 2 and 4: In a preferred embodiment the lift-roofstructure 22 is pivotally attached to a forward wall structure 28extending upward from the load bed wall 17 behind the cab 30, by meansof an inverted U shape outer frame 31 hinged to an inner frame 32 ofmatching shape with sealing means 33 at side interfaces 34 between theouter and inner frames 31, 32. The outer frame 31 is attached to aforward opening surround 36 in the lift-roof structure 22 and the innerframe 32 contains glass 38 retained by a horizontal closure member 40.The outer and inner frames 31, 32 are attached to each other at an upperlateral hinge interface 41 by telescopically assembled interlockingextruded male and female hinge halves 42, 44, respectively, of asectional form similar to those illustrated by McGaughey et al, U.S.Pat. No. 4,496,185 (FIG. 1 a) and Grise, U.S. Pat. No. 4,452,482 (FIG.2).

Vertical adjustability of the forward wall 28 relative to lift-roof 22is needed to ensure correct relationship of the forward wall lower edge46 relative to side wall rails 24 and the interfacing load bed 11, inclosed condition. This adjustment may be made when the forward wall 28is first installed to the lift roof structure 22 during the assemblyprocess by control of a range of overlap 47 between the lift-roof 22 andthe outer frame 31 to which the lift-roof 22 is attached. If adjustmentis later needed relative to a load bed 11 with which the lift-roof cover10 is to be used, increased convenience is desirable. Therefore, in apreferred embodiment, the forward wall 28 may include a lower member 48adjustably attached via accessible attachment means 50. Relativerigidity of the hinge interface 41 protects the upper seal interfacesfrom excessive compression. However, in a closed condition forwardloading is transferred disproportionately toward the lower edge 52 ofthe seal interface 34 by the lift-roof side walls 19. This results in atendency for the sealing means 33 and interfacing radius door frames 31,32 to be distorted toward the lower edge 52, eventually impairing bothsealing and positioning of the lift-roof 22 on the load bed 11. Toprevent these conditions and provide improved control of closed locationof the lift-roof 22 on the load bed 11 and relative to the forward wall28, forward wall to lift-roof structure adjustable stop and sideretainer means 54 are employed at each side.

Referring to FIGS. 1, 2, 5 and 6: Reliable weather sealing between theforward wall 28 and lift-roof structure 22 below the hinge interface 41is achieved on each side of the forward wall 28 with auxiliary sealingmeans 60 mounted to the inner frame outer surface 62 and seating againstthe facing inner surface 64 of outer frame 31. At lower levelssubstantially vertical surface continuation 66 below the inner frameouter surface 62 faces a matching surface continuation 68 below andpreferably coplanar with the outer frame surface 64 and inside edge 25of rail 24, so that seal 70 mounted to said lower surface continuation66 seats against the matching outer surface continuation 68 when thelift-roof 22 is closed. The lower seal 70 extends forward from below theauxiliary seal 60, so that rain water running down the forward edge ofseal 60 drops onto seal 70 and is carried over the load bed forward wall17.

Referring to FIG. 1 and FIG. 3: Further improvement results from the useof draw latches 72 uniquely developed for convenience in operation ofthe lift-roof cover 20. Improved draw latches 72 are mounted to latchand strut pivot mount brackets 73 attached to each lift-roof rail 24 toform a part of the lift-roof structure 22. In the manufacturing process,the draw latches 72 and lift assist struts 74 together with rigid struts75 are pre-assembled to the brackets 73 to form latch and strut pivotmount subassemblies 76, which are then held for installation to thelift-roof structure 22, thus simplifying the final assembly process.Lifting force exerted by the lift strut 74 tends to distort the loweredge 23 of the side wall 19. Because such force is absent in aconventional fixed cover installation to a load bed, stiffness istypically insufficient to avoid visible distortion in a lift-roofadaptation, particularly under reflected light conditions. Visibledistortion can be eliminated by increasing bending and torsionalstiffness along the side wall structural rail 24. However, a less costlymethod in adapting a cover of the prior art to lift-roof functionwithout degrading appearance has been found to be by transferring strutlift force to an upper area of the side wall 19 as a side force.Accordingly, latch and strut pivot mount bracket 73 incorporates sidewall structural reinforcing means 79 projecting upward from a levelclose to the lower edge 63 of the window 14 against the lift-roof sidewall 19 and hidden from external view behind window frame structure 65typically present in a conventional cab high cover of the prior art.

Some caps of the prior art are molded with an inside downward orientedlip 67, so that the lip 67 overlaps the flange 16, thereby providingcontrol of lateral location when sitting on a load bed 11. In a lift-capapplication such a lip is removed in locations adjacent to componentswhere interference may otherwise result, as at forward wall attachinglinkages 80 and latches 72. For lift-roof adaptation of molded caps nothaving such a lip, brackets 73 mounted to the rails 24, each with aninboard surface 68 substantially coplanar with the load bed flange 16provide a convenient option of adding a lateral locating means 69,optionally attached by rigid strut attachment means 78, the locatingmeans 69 having a ramped leading edge 71 suitable for providing preciselateral location on the load bed 11 when the lift-roof 22 is closed.

Referring to FIG. 1 and FIG. 2: A preferred forward wall to load bedattaching system is in the form of a linkage 80 at both sides 19 of thelift-roof cover 10, incorporating pivot links 81, attached via fasteningmeans 82 to a lower part 83 attached to, or forming part of, the forwardwall 28 at a pivot link upper slotted end 84, and via fastening means 85to a load bed inner flange forward attaching clamp means 86 at the pivotlink lower end 87.

In a preferred embodiment the load bed forward attaching clamp means 86is rigidly attached to a rearward attaching clamp means 88 via a bar 89,so forming a clamp link 90. Said rearward clamp means 88 is attached viafastening means 91 to a lower end 92 of a forward wall orientation link93. An upper end 94 of the orientation link 93 is attached via fasteningmeans 95 at an upper location 96 to each side of the forward wallstructure 28. In a preferred embodiment the upper location 96 isattached to, or forms a part of, inner frame 32, thus facilitatingpre-assembly. Thus, the forward wall structure 28, together with fourfastening means 82, 85, 91, 95, pivot link 81, clamp link 90 andorientation link 93 forms a linkage 80 at left and right sides of theforward wall 28. When fastening means 82, 85, 91, 95 are loosened,linkage 80 provides freedom of movement of component links 81, 90, 93,enabling adjustments in position of the links relative to forward wallstructure 28 and the vehicle load bed 11.

Multiple functions are accomplished with use of attaching linkage 80:with fastening means 82, 85, 91, 95 tightened to provide rigid joints,support is provided to control orientation of the forward wall 28relative to the load bed 11, plus means are provided for adjustinglongitudinal location of the lift-roof cover 10 on the load bed 11 andadjusting orientation of the forward wall 28 relative to load bed 11 toachieve effective sealing between the forward wall 28, lift-roof 22 andload bed 11 in a closed condition; means are also provided to completeinstallation or removal from the vehicle load bed 11 without need tofully remove attaching fastening means 82, 85, 91, 95; in conjunctionwith other components, means are provided to hold the forward wall 28 toa closed position relative to the lift-roof 22 with all componentssecured above a plane across lower edges 23 of the molded lift-roof 22,so that the lift-roof cover 10 may be shipped, handled and stored usingthe same methods employed for a conventional cap of the prior art.

Preferred fastening means 82, 85, 91, 95 for the attaching linkage 80include friction lock-nuts 107, so that fastening means 82, 85, 91, 95may be set with zero clamp load and yet maintain reliable attachment (asneeded to facilitate shipping). The friction lock-nuts 107 are used incombination with bolts 97 suitable for force-fitting to structuralcomponents so that tightening of fastening means 82, 85, 91, 95 islargely reduced to a one handed operation. Dimensions may be set sothat, in event of looseness at one location, as due to error, linkageengagement is still retained with the load bed side wall flange 16. Thelift-roof cover 10 is prepared for shipping with the forward wall 28held to a closed position as described above. This is accomplished byinstalling the latch and strut pivot mount bracket sub-assemblies 76 tothe lift-roof structure 22 with lift-assist struts 74 and strut lowerpivot brackets 98 positioned along the rail 24, forward of the latch andstrut pivot bracket 73 with the brackets 98 held in the linkage rearclamps 88, and with clamp links 90 and pivot links 81 in an upper,approximately horizontal position shown by the upper broken outline inFIG. 2.

Referring to FIGS. 8, 9, and 10: Where access between the load bed sidewall inner flange 16 and outer surface 13 is blocked or limited, as byload bed wall structure 100, toward the forward wall 17, a modified form101 of the preferred linkage 80 may be employed. An extension member 102of relatively rigid form such as having an angle cross section and ofhigh strength material, may be attached under clamp fasteners 103, 104inboard of the flange 16. The extension member 102 allows use of aforward clamp means 103 at a position where adequate access is availablebetween the flange 16 and the side wall outer surface 13 rearward ofattachment of the extension member 102 to pivot link 105. The desiredlateral, vertical and longitudinal control of forward wall positioningon the load bed 11 is thereby provided. A retaining angle bracket 106with adjustable means of attachment 108 to a horizontal face 109 on theextension member 102 may be used to engage the side wall flange 16 whereclearance between the flange 16 and blocking structure 100 is limited.Where no clearance is available, adjustments may be made to ensurelinkage contact is maintained at the forward end 111 with the flanges 16at both sides of the load bed 11, so providing control of lateralpositioning at the forward wall 28 relative to the load bed 11.

Referring to FIG. 1 and FIG. 2: Following installation of the latch andstrut pivot bracket assemblies 76 to the rails 24 with the lift assiststruts 74 lying forward along the rails 24, the forward wall 28,complete with attaching linkages 80 at each side, is installed andclamped into position in the same manner as for a conventional cap rearhatch 113 of similar construction. The forward wall 28 is then held to aclosed orientation relative to the lift-roof structure 22 and thelinkage rear clamp means 88 are clamped to the strut lower pivotbrackets 98 to maintain the forward wall closed relationship tolift-roof 22. The forward wall lower members 48 are then checked and, ifnecessary, adjusted for relationship to the lift roof lower edges 23.Side retainer/forward stop means 54 are, at this stage, installed to therails 24 at metal-to-metal interfacing component positions and shouldrequire no further adjustment when the lift-roof cover 10 is installedto a load bed 11.

Referring to FIGS. 1, 2, 13 and 14: Functional improvements also includerearward mounting of lift assist struts 74 between the vehicle load bed11 and the lift-roof rails 24 in a manner facilitating full closure atthe forward wall to lift-roof seal interface 34 when the lift-roof 22 islowered by forcing the lift-roof 22 forward against the forward wall 28,and also adding lateral constraint in location of the lift-roof 22relative to load bed 11. Geometry of the lift assist strut action issuch that, with the lift-roof 22 in a lower, closed position, verticalloading of the lift-roof 22 on the lift assist struts 74 exceedsvertical force provided by the lift assist struts 74, so that thelift-roof 22 will remain in a lower, closed position unless manuallyraised. The lift assist struts 74 are located close to the rail inneredges 25 and the load bed flanges 16 so that, if the lift-roof structure22 remained unlatched in error, the struts 74 constrain its laterallocation. When the lift-roof structure 22 is raised above the fullylowered position, the forward force provided by the lift assist struts74 pushes the lift-roof 22 against the forward wall structure 28 at thehinge interface 41. As the lift-roof 22 is lowered toward closed, anincreasing forward component of loading in the lift assist struts 74causes an increase in forward deflection of the forward wall 28 at thehinge interface 41 relative to the forward wall lower edge 46 due tocombined effect of flex in the forward wall structure 28 and flex in theload bed side walls 12 in the vicinity of the flanges 16 under tensileforce transferred through orientation links 93, until a lift-roofposition 114 (shown in broken line in FIG. 14) is reached where fullclosure has occurred at the forward wall to lift-roof seal interface 34.Due to the forward deflection of the forward wall 28 at the hingeinterface 41, relative to the forward wall lower edge 46, position 114occurs prior to full closure with the load bed 11, generally when thelift-roof 22 is at least a half inch clear of the load bed rear end 18.

Referring to FIG. 11: Installation is first a process of installing lowfriction/low stiction load bed interfacing seals 26 and positioning thelift-roof cover 10 on the load bed 11, in the same way as forconventional caps. After checking and, if necessary, adjusting function,the draw latches 72 are engaged with the flanges 16 to hold thelift-roof cover firmly in position.

Referring to FIG. 12 and FIG. 2: The forward wall adjusting linkage rearclamp fasteners 91 are then loosened to release the strut lower pivotbrackets 98, and the linkage 80 is rotated downward in direction ofarrow B so that clamp means 86, 88 may be swung down clear of the loadbed flange 16, then moved laterally inboard under the flange 16. Theclamp link 89 is then swung upward in direction of arrow C to engage theflange 16. If necessary, orientation link lower end 92 is at this timeadjusted to a position where the forward wall 28 is oriented with aclosed relation to the lift-roof 22. Forward clamp means 86 is movedupward, as accommodated by slot adjusting means 84 of pivot link 81, sothat flange 16 is engaged by forward clamp means 86. Clamp fasteners 85,91 are then tightened to appropriate torque levels, followed bytightening of fasteners 82 and 95.

Referring to FIGS. 2, 13 and 14: The latches 72 are next released and aset height installation strut 120 is attached by temporary attachmentmeans, (such as adhesive backed Velcro), 122 at one end to the lift roofstructure ceiling 123 adjacent to the lift-roof rear hatch 113. Thelift-roof structure 22 is then carefully raised until the installationstrut lower end 125 falls forward to the rear edge 126 of the load bed11 and is allowed to sit on the tailgate 128. Lift assist strut lowerpivot bracket 98, having been released when forward adjusting linkagefasteners 91 were first loosened, may now be rotated in direction ofarrow D to a location such as rear tie-down mountings where the lowerpivot bracket 98 can be bolted to the load bed 11. (Referring now toFIG. 2 and FIG. 14): After removing the set height installation strut120 and lowering the lift-roof 22, operating relationships for lift-roofside retainer/stop units 54 are checked and latches 72 again engaged forclosed mode operation.

Referring to FIGS. 1, 4, 5 and 6: Without countermeasures the lift-roofside wall forward lower edges 132 have increased potential for lateralvibration as compared with a conventional load bed cover, in which theside walls are integral to the forward wall. Such vibration is preventedcost effectively with stop and side wall retainer means 54 attached tothe lift-roof 22 at left and right sides 20, 21. To accommodatevariability in manufacture, stop and side wall retainer means 54incorporate means for adjustment of lateral relative position 134.

A preferred lift-roof adjustable side wall retainer and forward stopmeans 54 includes a first part or bracket 135 attached to a mount 136attached to and/or forming a part of the lift-roof structure 22, thebracket 135 having a face 137 on a substantially vertical andlongitudinal plane with a ramped leading edge 138 to guide engagementand prevent blocking due to minor misalignment of interfacing parts 135,83, the face 137 being substantially coplanar with a mating face 139 onflange 83, attached to or forming a part of the forward wall 28. Thebracket 135 and flange 83 each also have interfacing stop surfaces 140,141 so that, as the lift-roof 22 is lowered to a closed condition, thestop surfaces 140, 141 make positive contact. The bracket 135 isattached to the mount 136 via fastening means 142, comprising a bolt 143passing through slotted and/or oversize holes 134 in the mount 136 orbracket 135, the bolt 143 being retained by a friction lock-nut 145. Thebolt is constrained from rotation by interference or force fitting toone part, while an adjustment slot is provided in the other, thusallowing the friction lock-nut 145 to be torqued to provide clamping, orloosening of the bracket 135 relative to the mount 136 using one handand one tool. The use of slotted and/or oversize holes 134 accommodatesrelative lateral position adjustment between the first part 135 and themount 136. By varying the thickness of spacing means 146 between themount 136 and part 135, longitudinal position adjustment of the part 135relative to the mount 136 may also be provided. With the lift-roof 22 ina closed, lower position, the bracket 135 is set to bear forward againstflange 83 attached to or forming a part of forward wall structure 28.With the side retainer and closure stop adjustment means 54, closure ofthe lift-roof structure 22 relative to the forward wall 28 may be setduring the manufacturing assembly process as needed to ensuresatisfactory sealing between the lift-roof structure 22 and the forwardwall 28 and also to ensure that the possibilities of vibration oflift-roof structure side walls 19 relative to the forward wall 28 or ofunauthorized forced entry are eliminated. It will be recognized by oneskilled in the art to which the invention pertains that with simplerearrangement of components, the various described functions may bereversed between components attached to the forward wall 28 and thoseattached to the lift-roof 22 without departing from the scope of theinvention. (Referring to FIG. 7): It will be also be recognized that analternate bracket 147 may be easily fabricated to capture flange 83 onboth sides and by similar means vertical capture may also be achieved.

Referring to FIG. 15 and FIG. 16: Draw latches are used to draw and holdtwo structures together. The following describes limitations of two drawlatches of the prior art and how they are improved to meet functionalneeds for lift-roof operation. A first over-center draw latch of theprior art 150 comprises a latch hook 152, a latch handle 154 and a latchbase 156; the latch hook 152 being pivotally attached to the latchhandle 154 at pivot means 155, the latch handle 154 being pivotallyattached to the latch base 156 at pivot means 157. The latch base 156 isattached to a vertical surface 158 fixedly attached to, or forming partof, a first structure 22 and the latch hook 152 is used to engage asuitable engagement means 16 on the second structure 11. In latchedcondition (shown in broken outline in FIG. 15), tension force passingthrough the latch hook engagement point 159 with the second structure 11and through the latch hook pivot 155, holds the latch hook 152 to thelatched position until latch handle 154 is manually rotated away fromthe latch base 156 in direction of arrow L. Rotation of the handle 154per arrow L away and down from the latch base 156 brings the tensionforce line “over center” across the latch handle pivot 157 toward areleased condition (shown in solid line in FIG. 15), first lowering thelatch hook 152 from engagement with the load bed flange 16. To completefull release (referring now to FIG. 16), with upward rotation of thelatch handle 154 in direction of arrow M, the latch hook 152 should bemoved clear of the load bed flange 16 per arrow N. In reverse, with thecap shell 22 in the lowered position, downward rotation of the latchhandle 154 per arrow 0 first moves the latch hook 152 per arrow Pagainst the flange 16. With relatively low rotational friction levels,the latch hook 152 can be conveniently held in the position shown insolid line in FIG. 15. using a thumb while, with the same hand, thehandle 154 is rotated upward in direction of arrow Q, pulling the latchhook 152 into engagement with the load bed flange 16. As the handle 154is rotated further upward, the structures 11, 22 are drawn and held to alatched condition.

The first draw latch of the prior art 150, as available, is built withaxial clamp friction between components 152, 154, 156 at pivotinterfaces 155, 157 so that, without force beyond gravity, components152, 154 tend to remain in whatever relative position they are placed.However it has been found that initial operating efforts are too highfor convenience and the friction declines with use to levels where, withweight of the latch handle 154 bearing against the latch hook 152, thelatch hook 152 tends to fall under the flange 16 following initialdisengagement, resulting in interference with the side walls 15 whenlowering the lift-roof 22 from open, and/or re-engagement with the innerflange 16 when the lift-roof 22 is raised from closed.

Referring to FIGS. 1, 17 and 18: In a preferred embodiment, firstalternate improved draw latches 72 are mounted to the rails 24 and havelatch handles 164 which, when rotated to a fully latched/closedposition, pull latch hooks 166 into engagement with the load bed innerflanges 16, thereby drawing the lift-roof 22 down to the load bed 11.With appropriate vertical adjustment, this causes compression of sealingmeans 26 between the rails 24 and load bed side wall upper surfaces 15and prevents significant movement relative to the load bed 11. In thefirst improved draw latch 72 for use with a lift-roof cover, the latchhandle 164, in rotating downward, is positively limited at a lowerposition where the latch hook 166 hangs clear of engagement orinterference with the flange 16 when the lift-roof 22 is raised orlowered. The latch base 167 is mounted against a vertical surface 158forming a part of, or attached to, lift-roof side wall rail 24, with thelatch handle 164 pivoting from the latch base 167 and in a verticallyupward orientation when in fully latched mode. As modified for thelift-cap application, the latch base 167 is formed at a lower end 168 tocreate a positive stop 170 for the latch handle 164 at a position wheresaid latch handle is oriented down from its near vertical latchedposition and the latch hook pivot 172 is substantially inboard of thelatch handle pivot 174, following release of the latch hook 166 from theload bed flange 16. The first improved draw latch 72 is substantiallyfree of rotational friction drag at the latch hook pivot attachment 172and the latch hook 166 is modified from the first draw latch of theprior art 150 as by removal of material 176 so that, when the handle 164is rotated downward against the stop 170, the latch hook 166 can hangfreely and remain clear of the load bed wall upper surface 15. Thisallows the lift-roof structure 22 to be freely lowered toward a closedposition before, with easy one-handed operation, moving and holding thelatch hook 166 under the flange 16, while rotating the handle 164 towardvertical to engage the latch hook 166 with the flange 16 and pull thelift-roof structure 22 to a fully latched position.

Referring to FIGS. 19, 20 and 21: A second over-center draw latch of theprior art 178 includes a base 179, a latch handle 184 pivotally attachedto the base 179 at a pivot 185, and a latch hook 180 pivotally attachedto the handle 184 at a hook pivot 183. Retention means 181 temporarilyretain the latch handle 184 in an upward vertical orientation with thehook pivot 183 in a lower released position (shown in FIG. 20). However,the latch hook 180, following disengagement, remains in a positiondetermined by relation of its center of gravity 182 to its pivot 183,about which it freely rotates. This position may be such as either tointerfere with the load bed wall upper surface 15 when the lift roof 22is lowered and re-engage the load box inside flange 16 when it israised, or otherwise to fall clear and remain clear of the flange 16when engagement is desired. The relation of the latch hook 180 to thelatch handle 184 is such that its position cannot easily be controlledwhile also operating the handle 184 with the same hand.

Referring to FIG. 22 and FIG. 23: In a second alternate improvedlatching means 186 suitable for lift-roof cover application, theaddition of reliable friction means 188 acting relative to rotation ofthe latch hook 190 about its pivot 192 facilitates operation of thelatching function as a one-handed operation, allowing simultaneouslatching at left and right sides 20, 21 when the lift roof cover 10 isclosed. Reliable rotational friction drag is provided by use of leafspring 194 bearing against a circumferential surface 196 of the latchhook 190 where the circumferential surface 196 wraps around the pivotpin 192. It will be recognized by one skilled in the art to which theinvention pertains that wear in the friction interface 188 between theleaf spring means 194 and the latch hook circumferential surface 196will not quickly change normal force at the friction interface 188. Thisis because, unlike friction methods commonly employed in over-centerdraw latches of the prior art, friction drag is controlled by springdeflection, which will be large relative to any change in deflectionresulting from wear. Therefore, friction drag can be expected to beadequately maintained over a lift-roof cover functional lifetime. Whenthe latch handle 200 is raised, the latch hook 190 is first lowered and,as the hook 190 clears the flange 16, added friction drag exceeding theeffect of gravitational force, which gravitational force otherwisecauses the latch hook 190 to hang substantially vertically below hookpivot 192, causes the latch hook 190 to be rotated inboard and upwardwith latch handle 200 in direction of arrow R. This ensures that, withthe latch handle 200 retained to an upward vertical orientation, thelatch hook 190 will not re-engage the flange 16 when the lift-roof 22 israised to an open position, nor interfere with the load bed side wallupper surface 15 when the lift-roof 22 is lowered. Also, from thisposition, with the lift-roof 22 in a lowered position, if the latch hook190 is first independently manually rotated substantially downward fromits resulting position relative to the handle 200 following release, theadded friction ensures that the latch hook 190 will move against, and beheld against, the load bed inside flange 16 until the latch hook 190 hasfully engaged, when the latch handle 200 is then fully rotated downwardto draw the latch hook 190 upward.

The improvements of the present invention relating to a load bedlift-roof cover are defined by the following claims:

1. A load bed lift-roof cover including a lift-roof to forward wall stopand side wall retainer means comprising a first part attached to theforward wall structure and interfacing a second part attached to thelift-roof structure; at least one of the parts including a surfacehaving a ramped leading edge and extending on a substantially verticaland longitudinal plane, the surface being substantially coplanar with aninterfacing surface on the other part; the first and second parts alsoeach having interfacing stop surfaces.
 2. A load bed lift-roof cover asdescribed in claim 1 incorporating means of adjustment in relativelateral positioning of the substantially coplanar interfacing surfaces.3. A load bed lift-roof cover as described in claim 1 incorporatingmeans of adjustment in relative longitudinal positioning of theinterfacing stop surfaces.
 4. A load bed lift-roof cover as described inclaim 1 incorporating means of adjustment in relative lateralpositioning of the substantially coplanar interfacing surfaces andincorporating means of adjustment in relative longitudinal positioningof the interfacing stop surfaces.
 5. A load bed lift-roof coverincluding a system for attachment of a lift-roof forward wall to a loadbed at left and right sides, the system at each side being in the formof a closed linkage comprising four members including the forward walland three links; the links including a first link attached by a firstfastening means at a first location to the forward wall and by a secondfastening means at a second location to a second link; the second linkbeing attached by a third fastening means at a third location to a thirdlink; the third link being attached by a fourth fastening means at afourth location to the forward wall; the first, second, third and fourthfastening means being able to be loosened in a manner whereby thenormally fastened members remain attached to each other whileaccommodating relative rotation.
 6. A load bed lift-roof cover includingan over-center latch for drawing and holding a lift-roof to a closedposition on a load bed, the over-center latch comprising a latch hook, alatch handle and a latch base; the latch hook being pivotally attachedto the latch handle at a latch hook pivotal attachment, the latch handlebeing pivotally attached to the latch base at a latch handle pivotalattachment, and the latch base being fixedly attached to the lift-roofstructure; when latched, the latch handle and latch hook havingsubstantially vertical orientations, so that inboard rotation of thelatch handle about its pivotal attachment to the latch base lowers thelatch hook toward disengagement from the load bed; the latch includingmeans for releasably retaining the latch handle in an upward roientationrelative to the handle pivotal attachment; the latch hook and handleforming an interfacing pair having two members, including a first memberincorporating a surface circumferential to the axis of the latch hookpivotal attachment, and a second member incorporating friction meansrotating with the second member relative to the member; friction meansacting under spring force normal to the circumferential surface in amanner allowing the hook to be easily positioned at a desiredorientation relative to the handle and thereby retaining in thatposition.
 7. A load bed lift-roof cover including pivotal attachment ofa lift-roof to a forward wall, the forward wall comprising substantiallya hatch door including a window mounted in an inner frame of generallyinverted U-shape, the window being retained within the inner frame by alateral closure member joining sides of the inner frame; the inner framebeing pivotally attached across a lateral edge to an outer frame ofmatching inverted U shape by hinge means comprising interlocking hingehalves projecting from the inner and outer frames; the outer frame beingattached to the lift-roof at a forward opening in the lift-roof.